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Digital Thread & Digital Twin: The Winning Factor in Food & BeveragePresented by Suzanne Kopcha | Vice President Siemens PLM
Manufacturing in America │ March 20-21, 2019
Unrestricted © Siemens 2019
Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.
“There are no
consequences in
the virtual
world”Anton Huber | 2005
Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.
RealVirtual AutomationPLM Software
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Siemens saw big change coming in 2007
<1998 2000 2002 2004 2006 2008 2010 2012 2014 2016 2018-19
UGS
MentorMendix
TASSInfolyticaSarokalSolido
LMSTesis
CD-adapcoPolarion
Vistagy PerfectCosting
Kineo
ORSI ELAN VRConnectIBS
Active Camstar Bentley
SIMATIC Totally Integrated Automation
AUTOMATION #1
SOFTWARE #1OUR JOURNEY TO HELP COMPANIESREALIZE THE VALUEOF DIGITALIZATION
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Digitalization is changing everything!
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`
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#1Industrial software
#1Automation
Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.
24,500+software
engineers
A top 10global software
company
1 million+connected
assets
250+Digital offerings
incl. digital services
and industrial
applications
Food & Beverage
Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.
The Digital Enterprise is a catalyst for continuous innovation in
Food & Beverage….
Digital Twin Product
Digital Twin Production
Digital TwinPerformance
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To gain the full advantages of digitalization you must create a
digital thread …and eliminate the boundaries between systems and
organization silos.
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Digital Twin Product
Digital Twin Production
Digital TwinPerformance
Virtualproduct
Virtualproduction
Realproduct
Real productionAutomation
Continuous improvement
Insights from performance with MindSphere
Ideal delivery
Collaboration Platform
Verification Validation
Specification Commissioning
What do you need to realize the full value of digitalization?
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Siemens Digital Innovation Platform
New business models
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Food & Beverage Digital Enterprise Value Streams
6 Process based value streams across the Digital Enterprise
Product designProduction
Planning
Production
Engineering
Production
ExecutionServices5
Integrated Program Management
Product Development Excellence
Plant Design & Optimization
Flexible Manufacturing
Process Design & Engineering
Quality & Traceability
Product Development
Excellence
Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.Collaboration Platform
Food & Beverage Value Streams
1. Integrated Program ManagementDelivering an intelligent digital thread across program, project and product management
TRACKING
KPI
Updates
PROGRAMProgram Manager
IDEATIONMarketing Manager
PROJECTProductManager
Campaign
Idea
PORTFOLIOPortfolio Manager
Project WBS Root Element
© Siemens AG 2018
June 2018Page 15 Siemens PLM Software
PROJECTCHARTER
Process GroupMaster Plan
Scope
SOW
PRODUCTCONCEPT
Brand Equity
Product
InstantiationRule
SKU(Base)
SKU(Variant)
PACKAGEDESIGNProcess Group Leader
Model Engineer Validate
Package
ARTWORKDEVELOPMENTProcess Group Leader
Concept Layout Design
Artwork
FORMULATEDPRODUCT DESIGNProcess Group Leader
Develop Test Comply
Material
MANUFACTURINGPROCESS PLANNINGProcess Group Leader
Transform Validate
BOP
PLANT AND LINEDESIGNProcess Group Leader
Plant
Plan Design Optimize
Program
Project
Brand Portfolio
Expectation
Potential
Release toDefinition
Release toInitiating
Release toClosure
Release toClosing
DISCOVERYMarket Analyst
Release toPlanning & Executing
Release toDelivery
StakeholderProject Approval
Application
Business Case
Market Analysis
Role Assignments
Progress Review Application
Progress Review Application
Progress Review Application
TargetRtM Milestone
Delivering discipline execution
Transparency for smarter, faster decision making
Maximize re-use of approved assets
Accelerate product launch
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Digital Thread
Recipe Transformation
Package Design and Simulation
Artwork Development
Integrated Program Management
Formulated ProductDesign
Laboratory Information Management
▪ Full transparency
▪ Fact based decisions
▪ Re-use intellectual
property
▪ Digital Asset Library
▪ Control Collaboration
▪ Tool integration
▪ Modelling and
simulation capabilities
▪ Reduce R&D efforts
▪ Requirements based
▪ Regulatory
Compliance
▪ Better lab efficiency
▪ Real-time
management
▪ Automated guidance
▪ Site Data available to
Development
▪ Recipe Transformation
Digital TwinProduct & Production Management
Lifecycle Management
Restricted © Siemens AG 2018
2018-04-09Page 16 Siemens PLM Software
Food & Beverage Value Streams
2. Product Development ExcellenceDesigning the finished product in a seamlessly integrated system increases productivity,
quality and efficiency.
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Formulated Product Design
Supplier Specifications Formula Experiments Lab Quality Transformation
Collaboration ManufacturingResearch DataWorkbenchFoundation Quality
Formulated Product Design
Food & Beverage Value Streams
2. Product Development Excellence – Formula DesignNext generation integrated design with an improved user experience leveraging HTML,
Cloud and Mobility
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Food & Beverage Value Streams
2. Product Development Excellence – Formula OptimizationLeveraging HEEDS optimization to dramatically reduce cost – increase efficiency – and
formulate a new way.
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Food & Beverage Value Streams
2. Product Development Excellence – Artwork Design 2.0Digital, agile, accurate artwork solution reduces the cost and time of artwork by >50%
BUSINESS PROBLEM
Artwork is the long tail in the
innovation process.
• very manual
• often delaying initiative launch
• increasing recall risk.
• little to no agility
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Food & Beverage Value Streams
2. Product Development Excellence – Artwork Design 2.0Seamlessly integrate Finished Product elements for speed, quality and efficiency –
dramatically increase reuse of pre-approved assets
Digital Artwork Development
Artwork Development is dependent on input from other process groups,
• Package Design: Use Die Linegenerated by the flattening process from Package Design process group
▪ Formulated Product Design: Link Specification Content for the Product to Digital Assets used in the Artwork Development process group
ARTWORKDEVELOPMENT
PROGRAMLIFECYCLE
PACKAGEDESIGN
FORMULATEDDESIGN
Package Die Line
Formula Recipe Specification
Concept Layout Design
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Food & Beverage Value Streams
2. Product Development Excellence – Artwork Design 2.0Bringing Digital Artwork to the Designer’s world
Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.
Teamcenter Extension: Portfolio Management
Shorten time to market for new product launches by increasing stakeholder collaboration
SAP ERPSales Volume and Regional Stock
TeamcenterNew Product Introduction Process
R&D SuiteLIMS (Recipe Management)
low code platform
Pushnotifications
TeamcenterBOM data
Intuitive tablet dashboard
Ideacreation
R&D Suiterecipe data
Business case creation
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Food & Beverage Value Streams
3. Process Design & Engineering
Design Alternatives
Validate & Explore DesignsMeet multiple performance constraints
Scale-up & Performance EvaluationVirtual scale-up test
Reduce time & Increase confidence
Evaluate design sufficiency
Evaluate system performance
Reduce Risk & Operational Sweet-spotsControl Strategy & Testing
Virtual commissioning
Safety scenarios evaluation
Operation
•Scheduling
•Quality
•Process Orchestration
•Genealogy
•Logistics and material flow
Troubleshoot
•Reliability engineering
•Predictive maintenance
Data analysis,
experiment design
Conceptual
process design
Catalyst design
and analysis Troubleshooting
Model-based
automation
Design of
operating policy
Detailed
equipment design
Process
optimization
Control design
and verification
Front-end
engineering
design (FEED)
Utilities
optimization
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Food & Beverage Value Streams
3. Process Design & Engineering
Start CCM+, HEEDS and Virtual Commissioning Solutions
Engineering Time
30%
Technology
Transfer
Virtual Commission of Unit Operation
Time to Martket
Up to 35%
Cost of Trials
$MILLIONSReduce
Cost of trials
Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.
10xENGINEERING DESIGN EFFFECIENCY
SPEED OF INNOVATION
OPTIMAL DESIGN DISCOVERED
Restricted © Siemens AG 2019
Siemens PLM Software
Food & Beverage Value Streams
3. Process Design & Engineering
Optimized engineering design &
scale-up from months to weeks,
enables global expansion
in record time
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Food & Beverage Value Streams
4. Plant Design & Optimization
Capital Project Value Chain
feasibility &planning
FEED & detailedengineering
construction &commissioning
Optimization & maintenance
modernization &decommissioning
1 2 3 4 5
Project Planning and Execution Ops & Maintenance
A data-driven, capital asset management solution that
connects the entire lifecycle via a common digital thread
Restricted © Siemens AG 20XX
XX.XX.20XXPage 27 Author / Department
Food & Beverage Value Streams
4. Plant Design & Optimization: Trends in Construction
Increased global
competition
Increased project
size and complexity
Increased rate of
technology
innovation
Decreased labor
force
Restricted © Siemens AG 20XX
XX.XX.20XXPage 28 Author / Department
Food & Beverage Value Streams
4. Plant Design & Optimization: Capital Project by the numbers
80%is the average cost
increase of the original
value
98%of projects incur cost
overruns or delays
20 monthsaverage slippage
behind original
schedule
Source: McKinsey Construction Productivity Imperative Source: McKinsey Construction Productivity ImperativeSource: McKinsey Construction Productivity Imperative
Restricted © Siemens AG 20XX
XX.XX.20XXPage 29 Author / Department
Digital Thread
Digital Enterprise
Engineering Data
Advanced Capital Project
Planning & Execution
Digital Thread
Seamless Handover to
Operations & Maintenance
Food & Beverage Value Streams
4. Plant Design & Optimization: Digital Thread
Restricted © Siemens AG 20XX
XX.XX.20XXPage 30 Author / Department
Engineering - the systems view of what
needs to be built & operated “The integration of
engineering and
construction” Construction - the “path of construction”
view detailing how and when to build
Food & Beverage Value Streams
4. Plant Design & Optimization: Digital Twin and Digital
Thread are critical
Restricted © Siemens AG 20XX
XX.XX.20XXPage 31 Author / Department
Modernization &
Decommissioning
Food & Beverage Value Streams
4. Plant Design & Optimization: Siemens and Bentley
Partnership deliver Digital Twin of Intelligent Plant
Dynamically manages complex capital projects
Removes boundary between plant and enterprise data
Combines Bentley’s iModeland CDE with Teamcenter
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XX.XX.20XXPage 32 Author / Department
Siemens can enable companies to …
• Bringing PLM and plant CAD interoperability to facilities
• Scan existing facilities to accelerate virtualization of their
operations
• Virtually develop plants and lines to improve facility
changes or development
• Simulate operations virtually to evaluate changes or
optimize existing facilities
• Utilize this data to continually maintain and optimize plants
• Leverage factory design management to collaborate among
diverse teams
Digital Twin Production
Collaboration Platform
Food & Beverage Value Streams
4. Plant Design & Optimization: ….there’s much more than new
construction
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XX.XX.20XXPage 33 Author / Department
Virtualproduct
Virtualproduction
Realproduction
Realproduct
Digital TwinProduct
Digital TwinProduction
Digital TwinPerformance
Ideal
delivery
Collaboration platform: Teamcenter
Verification
Specification
Validation
Commissioning
Food & Beverage Value Streams
5. Flexible Manufacturing: To become radically Faster, more Agile and
Efficient we need to work in the virtual world of the Digital Twin
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XX.XX.20XXPage 34 Author / Department
Manufacturing digitalization
The widening gap in digital productivity
2001
TOP 5% PERFORMERS
REST OF THE INDUSTRY
Perc
ent
Incre
ase in labor
pro
ductivity
2005 2009 2013 2018
+25%
Source: The future of productivity report, 2015, OECD
0
-10
10
20
30 The top 5%of companies are dominating the
economy by exploiting digital competencies.
Source: It Pays To Be Smart, July 2017, MIT Technology Review
The Best Versus the Rest: The Global Productivity Slowdown, Divergence Across
Firms And The Role of Public Policy, OECD Productivity Working Papers
Restricted © Siemens AG 20XX
XX.XX.20XXPage 35 Author / Department
Realproduct
Digital TwinPerformance
Ideal
delivery
Virtualproduct
Digital TwinProduct
Virtualproduction
Realproduction
Collaboration platform: Teamcenter
Validation
Commissioning
We’ve seen that working virtually in the digital twin of production can
generate and validate designs with high speed and efficiency
But what’s the point of all that
simulation if your factory operates blindly or by the
whim of the individual operator?
To deliver transformative value to your customer, design and planning
software must always be combined with Flexible Manufacturing
Food & Beverage Value Streams
5. Flexible Manufacturing: but virtual without real won’t deliver Flexible
Manurfacturing
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XX.XX.20XXPage 36 Author / Department
MES – Current State
The first step towards Flexible (or Smart) Manufacturing
“…Industrial firms need to look
much wider than just connecting
the shop floor to business
operations. Collecting
manufacturing data is not the
raison d'etre of a program, but
rather a necessary step to
achieve corporate strategic
goals.
© LNS Research, 2017. All Rights Reserved.
More than 50% of the
Installations are “home-grown”
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XX.XX.20XXPage 37 Author / Department
Many customers are operating factories with
machines from the 1970s and margins are tight.
Flexible manufacturing will be a journey.
Customer must determine which stage is most
appropriate.
Capable of executing lot
size one on newly
introduced products with
zero defects.
Equipment is predictively
maintained and downtime is
sold through Smart
Contracts on a Blockchain
marketplaceNo transparency
Data Collection &
Performance ReportingReady to optimize
and systemize
operations
MES Looking to mass
customize whilst
squeezing additional
efficiencies from
production system
Smart
Manufacturing
Level 1 Level 2 Level 3 Level 4
Food & Beverage Value Streams
5. Flexible Manufacturing: Maturity Model
Factory of
the Future
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Siemens PLM Software
The MOM evolution towards Smart Manufacturing
Stand-alone MES• Focus on vertical integration
• Rich set of Industry-specific OOTB functionalities
• Real-time data acquisition
Monolithic MOM• From execution to a broader
coverage of manufacturing disciplines
• Scalable solutions, extensibility and code-less configuration
• Data synchronization and contextualization
MOM for Smart Manufacturing• Focus on collaboration through
horizontal integration
• Cloud-ready technologies
• Orchestration based on principles of Artificial Intelligence
• Augmented data contextualization through IoT
Improved
manufacturing
execution
Manufacturing
digitalization
Digital Enterprise
& Industry 4.0
’90s
’00s
Today
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Siemens PLM Software
MOM’s evolution towards Smart Manufacturing
Virtual product
Virtual production
Smart orchestrationof manufacturing and quality operationsSmart integration with PLM
Smooth design and engineering transfer
Smart data contextualizationwith manufacturing information
Real
product
Contextualized
Data
Closed Loop Processesfor continuous and proactive improvements
Smart connection to
MindSphere
Tools Process
People
MOM
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Siemens PLM Software
Consolidated Manufacturing Operations Management
Portfolio
QualityMES
EMIAPS
MOM
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XX.XX.20XXPage 41 Author / Department
Siemens makes 1 product
per second in our Amberg
facility with just 24 hours
of lead time
13x increase in efficiency
99.9999%
1,200quality rate
different products
Restricted © Siemens AG 2018
Food & Beverage Value Streams
6. Quality & Traceability
Consumers expect products to be safe, secure & authentic
But how can you
be sure where
they come from,
what they contain
and how they’ve
been handled?
???
Restricted © Siemens AG 2018
1
2
3
4
5
6
78
910
11
Food & Beverage Value Streams
6. Quality & TraceabilityComprehensive Quality systems require Product Quality, Manufacturing and
Materials Compliance, and Product Conformity
Restricted © Siemens AG 2018
Quality SystemsCritical Capabilities needed to deliver Comprehensive Quality Systems
Required By Siemens Solution
Compliance“Compliance” is ensuring both the
Product and the Manufacturing
Process meet the rules set by
regulatory bodies. It is enforced
through inspection.
1. Risk Assessment ISO9001-2015, FSMA, HARPC Compliant Pro
2. Regulatory Compliance FDA, ISO, FCC, EPA, TL9000 Compliant Pro
3. Personnel Compliance FDA FSMA, ISO, EPA, HARPC Compliant Pro
4. Supplier Compliance FDA, Market Demands Compliant Pro
5. Materials Compliance FDA, REACH, RoHS Teamcenter & Decernis
6. Quality Planning IATF16949, AIAG QMS Professional
7. Incoming Material Inspections IATF16949, AIAG QMS Professional
8. In-Process Inspections IATF16949, AIAG QMS Professional
9. Final Inspections IATF16949, AIAG QMS Professional
10. Quality Event Analysis FDA, ISO, EPA, etc. QMS Professional
11. Conformity Testing UL, CSA, CE, TUV, JED, etc. Unilab
Quality“Quality“ is act of ensuring the
product being manufactured is
consistently meeting the design
expectations. It is ensured through
in-line, at-line, and on-line
inspections
Conformity“Conformity” is act of ensuring the
product conforms to the safety
expectations set by regulatory
agencies such as UL, CE, TUV,
and CSA. It is ensured through the
destructive testing of samples
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Blockchain technology is expected to achieve
widespread, mainstream adoption sooner rather than
later. Retail and CPG businesses need to act now and
plan for future blockchain adoption, or risk being left
in the dust.
- Deloitte ‘18
“
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Am I being a good
supplier to my
customers?
Trusted Traceability: Win/Win/Win for every Stakeholder in the Supplychain
Are the ingredients
I’m using safe?
Are my operations
compliant and
efficient?
Are my products
being treated
correctly?
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Customers are already breaking down silos…and realizing the value
of digitalization.
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XX.XX.20XXPage 48 Author / Department
Constellation Brands partners with Siemens
to automate and modernize the world’s largest brewery
Standardizationof hardware and
software of more
than 30 different
equipment suppliers
Tripled annual
output while
maintaining product
quality
April 23, 2018 Dr. Jan Mrosik |CEO Digital Factory DivisionPage 48
Restricted © Siemens AG 20XX
XX.XX.20XXPage 49 Author / Department
Headline, Arial Bold, 22 pt, lorem ipsum dolor est
Content page – highlighted text
Digital Enterprise Suite
Unique portfolio for the
digital transformation
Unrestricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.
Questions?
Suzanne Kopcha
Presenter Vice President, Siemens PLM |Consumer Products &
Retail Industry
Address: 2000 Eastman Drive, Cincinnati, Ohio
Phone: 513-305-8968
E-mail:[email protected]